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Installation Testing Troubleshooting Starters Overload Relays
Installation Testing Troubleshooting Starters Overload Relays
E S P
SERVICE
MANUAL
c) R Pole ________________________
d) Y Pole _________________________
NOTE : If the answer is O.K. to all above points then only take the relay for
overload testing.
3.
Select the proper size of cable for connection. In case of smaller size of cable or
improper termination, relay may trip early.
4.
Connect all three poles of relay in series as shown in the following diagram.
Use proper size of cables. Length of cable should be one metre.
5.
Connect normally closed (NC) contact of relay in series with test panel's auxiliary
contact. (This will give relay trip to test panel.)
OVERLOAD TEST
FROM CURRENT SOURCE
1m
1m
DUT
1m
'NC' CONTACT
OF RELAY
1m
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30
E S P
SERVICE
MANUAL
Test Current
Amps
20 Amps
Eg.: 10 Amps.
2(200%)
1.
2(200%)
2.
3(300%)
7. Find out the minimum and maximum trip time with respect to multiples of set
current you have selected and note down the values in the following table.
Sr. No.
Relay
Setting
As per Curve
Min.
Remark
OK /
Not OK
Max.
1.
2.
8. Switch on the supply and adjust the test current. Immediately switch off the current. Keep
variac at adjusted position. Reset the time counter. Cool the relay for about 10 minutes.
9. Switch on the test current and check trip time of the relay.
Caution
After each test, cool the relay for minimum 10 minutes. Otherwise, relay will trip
early and you will not get correct results.
0 to 15
15 to 30
30 to 46
1.5
46 to 66 66 to 110
6
10
100 to 150
150 to 220
25
35
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31
E S P
SERVICE
MANUAL
1m
DUT
1m
'NC' CONTACT
OF RELAY
1m
CONNECTIONS OF THERMAL OVERLOAD RELAY
FOR SINGLE PHASE TESTING
Trip Time in
Sec. from
i-t characteristics.
Min.
Actual
Remark
OK /
Not OK
Max.
1.
2.
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32
E S P
SERVICE
MANUAL
4000
2000
1000
600
400
200
100
60
50
40
30
20
10
6
4
0.8
1.2
1.5
6 7 8
NOTE :
1. THE TRIPPING TIME FOR ANY CURRENT SHALL LIE BETWEEN THE VALUES
CORRESPONDING TO 90% AND 110% OF THAT CURRENT.
2. CURVE REPRESENTS COLD STATE CHARACTERISTICS.
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33
E S P
SERVICE
MANUAL
2000
1000
600
400
200
100
60
50
40
30
20
10
6
4
0.8
1.2
1.5
7 8
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34
E S P
SERVICE
MANUAL
2000
1000
600
400
200
MAXI. TRIP
TIME CURVE
100
60
50
40
30
MINI. TRIP
TIME CURVE
20
10
6
4
0.8
1.2
1.5
7 8
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35
E S P
SERVICE
MANUAL
4000
2000
1000
400
MAX. TRIP
TIME CURVE
200
115 SEC.
100
48 SEC.
40
20
MINI. TRIP
TIME CURVE
10
0.8
1.5
8 9 10
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36
E S P
SERVICE
MANUAL
4000
2000
1000
400
200
100
60 SEC.
40
20
11 SEC.
10
6
4
0.8
1.5
8 9 10
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37
E S P
SERVICE
MANUAL
10
MAX. SETTING
102
MIN. SETTING
101
0.6
1.2 1.5
10
L&T SWITCHGEAR
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38
E S P
SERVICE
MANUAL
WIRING DETAILS
MN16 DOL
L&T SWITCHGEAR
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39
E S P
SERVICE
MANUAL
WIRING DETAILS
MN16 FASD
MN16 SASD
L&T SWITCHGEAR
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40
E S P
SERVICE
MANUAL
WIRING DETAILS
L&T SWITCHGEAR
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41
E S P
SERVICE
MANUAL
WIRING DETAILS
ML1 DOL
ML1.5 DOL
ML1.5 FASD
ML1.5 SASD
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42
E S P
SERVICE
MANUAL
WIRING DETAILS
ML2 FASD
ML2 SASD
ML3 FASD
ML3 SASD
L&T SWITCHGEAR
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43
E S P
SERVICE
MANUAL
WIRING DETAILS
L&T SWITCHGEAR
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44
E S P
SERVICE
MANUAL
WIRING DETAILS
L&T SWITCHGEAR
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45
E S P
SERVICE
MANUAL
WIRING DETAILS
MK1 DOL
MK1 FASD
MK1 SASD
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46
E S P
SERVICE
MANUAL
S TA R D E LTA S TA R T E R S ( M L S E R I E S )
Timers
Contactors
STAR
DELTA
HOLD ON
ML 1.5
SASD
ML 1
ML 1.5
ML 1.5
ML 1.5
FASD
ML 1
ML 1.5
ML 1.5
GT-200
ML 2
SASD
ML 2
ML 2
ML 2
ML 2
FASD
ML 2
ML 2
ML 2
GT-200
ML 3
SASD
ML 2
ML 3
ML 3
ML 3
FASD
ML 2
ML 3
ML 3
ET-100
ML 4
FASD
ML 3
ML 4
ML 4
ET-100
ML 6
FASD
ML 4
ML 6
ML 6
ET-100
ML 10
FASD
ML 10
ML 10
ML 10
ET-100
ML 12
FASD
ML 12
ML 12
ML 12
ET-200
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47
E S P
SERVICE
MANUAL
Sr.
No
hp
kW
In
(A)
0.125
0.09
0.45
0.4-0.65
0.15
0.11
0.45
0.2
0.15
0.25
Contactor
Back up
fuse
SDF
Rating
Type
MLO
HF
FN32
0.4-0.65
MLO
HF
FN32
0.57
0.4-0.65
MLO
HF
FN32
0.19
0.7
0.6-1.0
MLO
HF
FN32
0.33
0.25
0.88
0.6-1.0
MLO
HF
FN32
0.5
0.37
1.2
1.0-1.6
MLO
HF
FN32
0.75
0.55
1.6
1.5-2.5
MLO
HF
FN32
1.0
0.75
1.8
1.5-2.5
MLO
HF
FN32
1.25
0.92
2.1
1.5-2.5
MLO
HF
FN32
1.5
1.1
2.6
2.5-4.0
MLO
10
HF
FN32
11
1.75
1.3
3.0
2.5-4.0
MLO
10
HF
FN32
12
2.0
1.5
3.5
2.5-4.0
MLO
10
HF
FN32
2.5
1.8
4.8
4-6.5
MLO
16
HF
FN32
14
3.0
2.2
5.0
4-6.5
MLO
16
HF
FN32
15
4.0
3.0
6.2
4-6.5
MLO
16
HF
FN32
0.125
In
Relay
Range
hp
kW
Motor Rating
215V-3 Phase
0.11
0.25
0.18
2.0
10
13
0.5
0.75
0.4
0.55
3.6
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E S P
SERVICE
MANUAL
Sr.
No
hp
Motor Rating
215V-3 Phase
kW
In
hp
kW
Relay
Range
In
(A)
Contactor
Back up
fuse
Rating
Type
SDF
16
1.0
0.75
7.5
5.0
3.7
7.5
6-10
MLO
20
HF
FN32
17
1.25
0.9
8.0
6.0
4.5
9.0
6-10
MLO
25
HF
FN32
18
2.0
1.5
9.5
7.5
5.5
11.0
10-16
MLO
25
HF
FN32
19
3.0
2.25
14.0
10.0
7.5
14.0
10-16
ML1
32
HF
FN32
20
12.5
9.3
18.0
13-21
ML1.5
50
HF
FN63
21
15.0
11.0
21.0
20-32
ML1.5
63
HF
FN63
22
17.5
13.0
24.0
20-32
ML2
63
HF
FN63
23
20.0
15.0
28.0
20-32
ML2
63
HN/00
FN100
24
25.0
18.6
35.0
28-42
ML3
80
HN/00
FN100
25
30.0
22.5
40.0
28-42
ML3
80
HN/00
Fn100
NOTES:
(1)
The full load currents given apply in the case of single phase motors, to capacitor-start type motors and in the
case of 3 phase motors, to squirrel cage type induction motors at full load having average power factor and
efficiency. The motors should have speeds not less than the following:
Upto 10 hp - 750 R.P.M., 10 to 30 HP - 600 R.P.M., 30 - 125 HP - 500 R.P.M., 125 - 300 HP - 375 R.P.M.
(2)
Contactors/Switches indicated are the minimum ratings suitable for the application. Higher sizes/Ratings can
be used.
(3)
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49
E S P
SERVICE
MANUAL
C H A R T F O R S TA R - D E LTA M O T O R S TA R T E R S
WITH ML RELAYS
Motor Rating
Sr.
No
Current
at 415 V (A)
Relay
Range
Nominal Back
up fuse link
Contactor
SDF
hp
kW
LINE
PHASE
(A)
STAR
LINE
DELTA
Rating
A
Type/
Size
0.75
1.8
1.04
1-1.6
MLO
MLO
MLO
HF
FN32
1.5
1.1
2.6
1.5
1-1.6
MLO
MLO
MLO
HF
FN32
1.5
3.5
2.02
1.5-2.5
MLO
MLO
MLO
HF
FN32
2.25
2.88
2.5-4.0
MLO
MLO
MLO
HF
FN32
6.2
3.58
2.5-4
MLO
MLO
MLO
10
HF
FN32
3.75
7.5
4.32
4-6.5
MLO
MLO
MLO
16
HF
FN32
4.5
5.2
4-6.5
MLO
MLO
MLO
16
HF
FN32
7.5
5.5
11
6.34
6-10
MLO
MLO
MLO
20
HF
FN32
10
7.5
14
8.08
6-10
MLO
MLO
MLO
20
HF
FN32
10
12.5
9.3
18
10.04
10-16
MLO
MLO
MLO
32
HF
FN32
11
15
11
21
12.1
10-16
MLO
Ml1
Ml1
32
HF
FN32
12
20
15
28
16.2
13-21
ML1
ML1.5
ML1.5
40
HF
FN63
13
25
18.5
35
20.2
13-21
ML1
ML1.5
ML1.5
50
HF
FN63
14
30
22.5
40
23
20-32
ML2
ML2
ML2
63
HF
FN63
15
35
26
47
27
20-32
ML2
ML2
Ml2
63
HN/00
FN100
16
40
30
55
31.8
28-42
ML2
ML3
ML3
63
HN/00
FN100
17
45
33.5
60
34.6
28-42
ML2
ML3
ML3
80
HN/00
FN100
18
50
37.5
66
38.2
28-42
ML2
ML3
ML3
80
HN/00
FN100
NOTES:
(1)
Contactors/Switches indicated are the minimum ratings suitable for the application. Higher sizes/Ratings can
be used.
(2)
For applications above 35 hp suitable scheme to be employed to ensure change over delay of 40-75ms
between star and delta contactors.
(3)
L&T SWITCHGEAR
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50
E S P
SERVICE
MANUAL
Motor rating in hp
Relay
scale
415V
3 phase
Amps
(A)
Cartridge
fuses
Rewritable
fuses SWG
0.125
0.4-0.65
4A
35
0.25
0.6-1.0
6A
32
0.5
1.0-1.6
6A
32
0.75
1.5-2.5
16A
25
1.0
1.5-2.5
16A
25
1.25
1.5-2.5
16A
25
1.5
2.5-4.0
25A
23
1.75
2.5-4.0
25A
23
2.0
2.5-4.0
25A
23
2.5
4.0-6.5
25A
23
3.0
4.0-6.5
25A
23
4.0
4.0-6.5
25A
23
0.75
4.5-7
25A
23
1.00/1.25
6.5-11
32A
21
5.0
6.0-10
32A
21
6.0
6.0-10
32A
21
10.5-17.5A
32A
21
9.0-15
32A
21
11-18
32A
21
12-20A
32A
21
240V
Single phase
0.125
0.25
0.5
2.00
7.5
3.00
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51
E S P
SERVICE
MANUAL
220
1-Phase
400V
3-phase
440V
4-phase
0.005
0.05
0.15-0.25
1A
0.1
0.1
0.25-0.4
2A
0.125
0.125
0.25-0.4
2A
0.15
0.15
0.4-0.65
4A
35
0.2
0.2
0.4-0.65
4A
35
0.25
0.4-0.65
4A
35
0.6-1.0
6A
0.5
1.0-1.6
0.75
0.25
0.75
SS96210
0.5
32
6A
32
6A
32
6A
32
1.0-1.6
6A
32
6A
32
1.0
1.5-2.5
15A
25
6A
32
1.0
1.25
1.5-2.5
15A
25
6A
32
1.25
1.5
2.5-4.0
25A
23
10A
28
1.5
1.75
2.5-4.0
25A
23
10A
28
1.75
2.0
2.5-4.0
25A
23
10A
28
2.5-4.0
25A
23
10A
28
0.5
Diazed
Minimum
SWG
2.0
0.75
Maximum
Diazed
0.25
0.125
Relay
Amps.
Range
SWG
2.5
2.5
4.0-6.5
25A
23
10A
28
3.0
3.0
4.0-6.5
25A
23
10A
28
4.0
4.0-6.5
25A
23
10A
28
6-10
35A
21
15A
25
1.0
4.0
1.25
5.0
5.0
6-10
35A
21
15A
25
1.5
6.0
6.0
6-10
35A
21
15A
25
9-14
35A
21
15A
25
1.75
2.0
7.5
7.5
11-18
35A
21
15A
25
SS96211
2.0
7.5
7.5
11-18
35A
21
15A
25
SS96228
2.0
7.5
7.5
13-22
40A
21
15A
25
Note :
Amp. Rating of back-up fuse refers to the recommended diazed type HRC catridge fuse. Where rewirable
semi-enclosed, tinned copper wire fuses are used, SWG number in table is approximate guide to size of wire
required.
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52
E S P
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MANUAL
C H A R T F O R M K 1 S TA R - D E LTA S TA R T E R
Cat No.
Motor
Full load
Rating
line
400/440v current
3-phase in Amps.
hp
ln
In
V3
Relay
Amps.
Range
Minimum
Diazed
SWG
Diazed
SWG
1.7
1-1.6A
32
35
1.5
2.4
1.4
1-1.6A
15
25
32
3.1
1.8
1.5-2.5A
15
25
32
SS96254
4.4
2.5
2.5-4A
25
23
32
&
5.7
3.3
2.5-4A
25
23
10
28
SS96255
7.1
4.1
4-6.5A
25
23
10
28
8.4
4.9
4-6.5A
25
23
10
28
7.5
10.4
6-10A
35
21
15
25
10
13.6
7.9
6-10A
35
21
15
25
12.5
17
9.7
9-14A
35
21
20
24
15
19.9
11.5
9-14A
35
21
25
23
15
19.9
11.5
11-18A
35
21
25
23
SS96257
&
SS96258
Note: Amp. Rating of back-up fuse refers to the recommended diazed type HRC catridge fuse. Where
rewirable semi-enclosed, tinned copper wire fuses and used, SWG number in table is approximate guide to
size of wire required.
Cat. No SS 96254 & SS 96257 - FASD Starters
Cat. No SS 96255 & SS 96258 - SASD Starters
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53
E S P
SERVICE
MANUAL
Type
MB1
DOL
MB2
DOL
MU1
DOL
MU2
DOL
Maximum
Motor rating at
145V.3 ph 50 HZ
HP
KW
7.5
5.5
Approx.
Full load
Current in
11
Relay
Range
(A)
Relay
Contactor
9-15
10
7.5
14
14-23
12.5
9.3
18
14-23
15
11
21
14-23
15
11
21
20-33
7.5
5.5
11
9-14
10
7.5
14
13-21
12.5
9.3
18
13-21
15
11
21
13.21
15
11
21
20-32
MN2
MN2
MU2
MU2
MU1
MU2
MU1
MU2
Back-up
HRC Fuse
Switch
Disconector
Fuse Unit
Type
Rating
(A)
HF
32
FN 32
HF
50
FN 63
HF
50
FN 63
HF
63
FN 63
HF
63
FN 63
HF
32
FN 32
HF
50
FN 63
HF
50
FN 63
HF
63
FN 63
HF
63
FN 63
S E L E C T I O N C H A R T F O R M U / M B S TA R D E LTA S TA R T E R S
Type
MB1
SASD
MB2
SASD
MU1
SASD
MU2
SASD
Maximum
Motor rating at
145V.3 ph 50 HZ
HP
KW
15
11
21
12.1
Relay Contactor
9-15
15
11
21
12.1
14-23
20
15
28
16.2
14-23
25
18.5
35
20.2
14-23
30
22.5
40
23
20-33
15
11
21
12.1
9-14
15
11
21
12.1
13-21
20
15
28
16.2
9-14
25
18.5
35
20.2
13-21
30
22.5
40
23
20-32
MN2
MN2
MU2
MU2
MU1
MU1
MU1
MU2
Back-up
HRC Fuse
Switch
Disconector
Fuse Unit
Type
Rating
(A)
HF
32
FN 32
HF
40
FN 63
HF
40
FN 63
HF
50
FN 63
HF
63
FN 63
HF
32
FN 32
HF
40
FN 63
HF
40
FN 63
HF
50
FN 63
HF
63
FN 63
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54
E S P
SERVICE
MANUAL
Maximum
submersible
pump rating
at 415 V,
3ph., 50hz
HP
Relay
Range
(A)
KW
Relay
Contactor
Type
Type
Type
Rating
(A)
Switch
Disconnector
Fuse Unit
2.2
4-6.5
MU 1
MU 1
HF
16
FN 32
3.7
6-10
MU 1
MU 1
HF
16
FN 32
7.5
5.5
9-14
MU 2
MU 1
HF
32
FN 32
10
7.5
13-21
MU 2
MU 1
HF
40
FN 63
3.7
6-10
MN 2
MU 1
HF
16
FN 32
7.5
5.5
9-15
MN 2
MU 1
HF
32
FN 32
10
7.5
20-32
MU 2
MU 2
HF
63
FN 63
10
7.5
28-42
MU 2
MU 2
HN/00
63
FN 100
MUG-10 DOL
MUG-10N DOL
MUG-10H DOL*
Note : MU 1/2 contactors are available in 415 V coil operating voltage also.
Note : MUG-10 DOL are available with dry run facility as a optional feature.
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E S P
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MANUAL
S E L E C T I O N C H A R T F O R M U G - 2 0 S TA R - D E LTA
SUBMERSIBLE PUMP STARTERS
Type
Maximum
submersible
pump rating
at 415 V,
3ph., 50hz
Relay
Range
(A)
Relay
Contactor
Type
Type
Type
Rating
(A)
Switch
Disconnector
Fuse Unit
HP
KW
MUG-20
15
11
9-14
MU 2
MU 1
HF
32
FN 32
Star-Delta
20
15
13-21
MU 2
MU 1
HF
40
FN 63
MUG-20H*
20
15
20-32
MU 2
MU 2
HF
63
FN 63
Star-Delta
20
15
28-42
MU 2
MU 2
HN/00
63
FN 100
Note : MU 1/2 contactors are available in 415 V coil operating voltage also.
Note : MUG-10 DOL are available with dry run facility as a optional feature.
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INFORMATION FOR INSTALLATION AND
PREVENTIVE MAINTENANCE
Cable connections to the terminals
When aluminium wires are used, the following method should be adopted:
If the wire is small up to 1 mm
Single strand
1. Clean the wire surface by rubbing with a small hard wire brush.
2. Tin the wire immediately (within 2 or 3 minutes).
3. Put wire under terminal clamp and tighten screws. Do not tighten to such an
extent that the wire becomes flat.
Every two or three months, it may be necessary to ensure that the screws are tight
and the wire has not become loose. This may happen because aluminium is soft and
is likely to flow. Always apply inhibiting grease around the terminal and wire to
prevent moisture from reaching the area of contact. Apply inhibiting grease, only on
the terminals and wire and not on the contacts.
If the wire is large larger than 10 mm2
Multi-strand
Wires should be connected with the help of cable lugs or thimbles. The cable lugs
may be of "soldering" or "crimping" type.
For "soldering" type cable lugs:
Check that cable lug socket is clean and dry inside.
Clean every strand of aluminium wire with a small hard wire brush by opening out
the cable strands.
Immediately dip all the strands in tin solder.
Insert the stranded cable in the proper size cable lug and pour solder through the
cable lug. Ensure that solder fills the entire space inside the cable lug socket.
Wipe off excess solder on cable insulation.
Connect the cable lug to the terminal and tighten terminal screws using spring
washers on the cable lug.
There should not be excess load on the cable lug, or else the solder will become
loose. Care must, therefore, be taken to cut the cable core and strip the insulation
to the correct length. The cable lug should sit flat on the terminal and the cable
should not have sharp bends.
Every two or three months it is necessary to check whether the connection is firm
and to tighten the screws, if necessary. Also check and ensure that the cable is
not loose in the cable lug.
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S E C T I O N VIII
Trouble shooting chart for starters
Given below are some of the common complaints in starters. The probable cause
and suggested remedy are also given. But before attending to any complaint,
ensure that the wiring is as per the wiring diagram given in this booklet. Most of the
complaints can be traced to the wiring carried out at the site.
Reasons / Solutions
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7. Thermostat/float
switch/pressure switch are
wired to the starter. Motor
cannot be stopped properly.
Motor stops on pressing stop
button. However it restarts on
releasing the same.
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INSTALLATION & COMMISSIONING OF THE MOTOR
CONTROLLER MU-G10 AND MU-G20
This controller is provided with several protection features and indicating instruments
for the convenience of operation and safety. The motor can be set to start
(automatically) within 30-60 secs. after supply is restored. For this, the rocker switch
on SPPR has to be set to "AUTO", otherwise set to "BY-PASS" mode. This feature is
by-passed as supplied from the factory.
The motor controller is armed with the following protection features:
1. Overload protection
2. Phase failure*
3. Phase unbalance *
4. Phase reversal *
5. Dry run protection (Not Standard)*
* - Protection features enabled only in AUTO mode and not in BY-PASS mode.
Visual indication is provided :
1. Supply Voltage (Line)
2. Current drawn by motor (Phase)
3. Lamp-indicating supply ON
4. Lamp - indicating motor ON
For normal operation (manual mode) motor can be switched ON-OFF with GREEN &
RED push buttons. Toggle switch should be in ON position.
However, please note that the standard RED push button will not function in "AUTO"
mode & toggle switch has to be used for switching OFF.
By taking these few precautions and care the starter will be able to perform
satisfactorily year after year.
installation & Commissioning of the motor controller MU-G10 and MlU-G20
A) Installation instruction:
Ensure that the enclosure is mounted in the vertical position.
Set the rocker switch on the SPPR to "BY-PASS" mode, the switch can be set to
"Auto" mode only after ensuring the proper operation of the motor for a few
minutes.
Use right size of the cables with cable lugs. Use cable glands for fixing cables to
the enclosure to avoid excess stress on terminals.
Connect the supply (Line) cables on the terminal block provided, Marked "Supply
terminals" in star-delta controller and in DOL controller on the MU contactor.
Connect the motor terminals on the terminal block provided, marked "Motor
terminals".
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PROBLEM
CAUSE
SOLUTION
1.
2.
Motor overloaded
Relay tripping
3.
Interchange Y&B on
the SPPR
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